US20230119577A1 - High alloy welding wire with copper based coating - Google Patents

High alloy welding wire with copper based coating Download PDF

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Publication number
US20230119577A1
US20230119577A1 US18/045,934 US202218045934A US2023119577A1 US 20230119577 A1 US20230119577 A1 US 20230119577A1 US 202218045934 A US202218045934 A US 202218045934A US 2023119577 A1 US2023119577 A1 US 2023119577A1
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United States
Prior art keywords
copper
welding
welding wire
metal core
high alloy
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Pending
Application number
US18/045,934
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English (en)
Inventor
Badri K. Narayanan
Nathanael M. COLVIN
Alexander J. ZADDACH
John Benjamin Schaeffer
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Lincoln Global Inc
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Lincoln Global Inc
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Priority to US18/045,934 priority Critical patent/US20230119577A1/en
Assigned to LINCOLN GLOBAL, INC. reassignment LINCOLN GLOBAL, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: NARAYANAN, BADRI K., COLVIN, Nathanael M., ZADDACH, Alexander J., SCHAEFFER, JOHN BENJAMIN
Priority to EP22801636.6A priority patent/EP4415923A1/en
Priority to CN202280064768.8A priority patent/CN117980105A/zh
Priority to PCT/US2022/046541 priority patent/WO2023064450A1/en
Priority to JP2024521230A priority patent/JP2024539608A/ja
Priority to KR1020247012025A priority patent/KR20240087837A/ko
Publication of US20230119577A1 publication Critical patent/US20230119577A1/en
Pending legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
    • B23K35/0255—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in welding
    • B23K35/0261—Rods, electrodes or wires
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550°C
    • B23K35/302—Cu as the principal constituent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550°C
    • B23K35/3053—Fe as the principal constituent
    • B23K35/3066—Fe as the principal constituent with Ni as next major constituent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550°C
    • B23K35/3053—Fe as the principal constituent
    • B23K35/3073—Fe as the principal constituent with Mn as next major constituent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550°C
    • B23K35/3053—Fe as the principal constituent
    • B23K35/308—Fe as the principal constituent with Cr as next major constituent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550°C
    • B23K35/3053—Fe as the principal constituent
    • B23K35/3093—Fe as the principal constituent with other elements as next major constituents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/40—Making wire or rods for soldering or welding
    • B23K35/404—Coated rods; Coated electrodes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/02—Iron or ferrous alloys
    • B23K2103/04—Steel or steel alloys
    • B23K2103/05—Stainless steel

Definitions

  • the present disclosure generally relates to consumable welding electrodes and welding processes utilizing the same.
  • welding wires may serve as an consumable electrode that function as a source of metal for forming a weld on a workpiece, and a mechanism for providing flux and other weld performance additives.
  • an electric arc is created when a voltage is applied between the welding wire (a first electrode) and the workpiece (a second electrode).
  • a first electrode the welding wire
  • a second electrode the workpiece
  • an arc forms between the electrodes, melting the tip of the welding wire and producing a weld bead of molten metal at the point of contact on the workpiece.
  • the welding wire is continuously fed into the welding system, providing a stream of molten metal that generates the weld on the workpiece.
  • the chemical composition, physical state, and presence of layers and coatings on the welding wire can all impact a number of weld properties.
  • Welding wire chemical metal composition can alter bead and weld quality in both appearance and mechanical properties, including yield strength, ductility, and fracture toughness.
  • the structural properties of the welding wire can also impact other components of the welding system.
  • the feed system and contact tip for example, experience friction and electrical resistance that is dependent on the properties of the welding wire, which can affect mechanical wear and overall service life of these system components.
  • welding wires disclosed herein may include a high alloy metal core comprising greater than about 10.5 percent by weight of the high alloy metal core of a component selected from aluminum, bismuth, chromium, molybdenum, chromium/molybdenum alloy, cobalt, copper, manganese, nickel, silicon, titanium, tungsten, vanadium, or a combination thereof; and a layer surrounding the high alloy metal core, the layer comprising copper or a copper alloy.
  • welding methods disclosed herein may include applying an electrical current sufficient to convert a welding wire to a molten state to produce a molten weld material, the welding wire comprising: a high alloy metal core comprising greater than about 10.5 percent by weight of the high alloy metal core of a component selected from aluminum, bismuth, chromium, molybdenum, chromium/molybdenum alloy, cobalt, copper, manganese, nickel, silicon, titanium, tungsten, vanadium, or a combination thereof; and a layer surrounding the high alloy metal core, the layer comprising copper or a copper alloy; and depositing the molten welding material onto a workpiece.
  • a high alloy metal core comprising greater than about 10.5 percent by weight of the high alloy metal core of a component selected from aluminum, bismuth, chromium, molybdenum, chromium/molybdenum alloy, cobalt, copper, manganese, nickel, silicon, titanium, tungsten, vanadium, or a combination
  • FIG. 1 is an embodiment of a coated wire in accordance with one embodiment.
  • FIG. 2 is a flow diagram of a non-limiting embodiment of a welding method.
  • welding wire compositions disclosed herein exhibit reduced contact tip wear and improved electrical properties.
  • welding wire compositions disclosed herein include a high alloy core coated with a layer of copper or copper alloy.
  • the layer of copper or copper alloy may form a conductive layer that also exhibits improved compatibility with copper contact tips, while also reducing mechanical and electrical-induced wear.
  • high alloy welding wire may have a number of advantages including fine appearance, corrosion resistance, tarnish resistance, and oxidation resistance at elevated temperature.
  • high alloy welding wire often exhibits higher tensile strength and surface hardness that can increase the wear on the wire feeding components of the welding system, which are often composed of softer metals and alloys.
  • the conductivity difference between the high alloy wire and the contact tip (often constructed from copper) also contributes to arc formation and burnback that can lead to clogging and feed issues.
  • high alloy welding wire is often used in the unclad form, or with a non-metal coating such as silicone, to form welds that are naturally corrosion resistant, and have excellent weld appearance and strength.
  • Copper coatings have been used to coat low alloy solid metal and flux-cored welding wires to improve corrosion resistance, enhance conductivity, reduce contact tip deterioration, and lubricate the wire during drawing and feeding through the welding apparatus.
  • the use of copper coatings may also be accompanied by a number of disadvantages. Copper metal is soft and tends to create flakes of copper metal during the forced feeding of the wire through the weld system, including through the liner, torch, and contact tip.
  • copper flakes can cause a number of mechanical issues, including the formation of aggregates that form clogs or electrical contact points that can cause hotspots. Worse still, copper flakes may induce a form of liquid metal embrittlement, or “copper cracking” that damages the strength of the weld.
  • copper flakes may be melted by molten slag and transferred to the weld bead. As the bead metal and cools, copper remains molten and migrates to the grain boundary of the solidified metal. Within the grain boundaries of the weld, the soft copper metal forms weak points that weaken the weld and/or workpiece metal.
  • welding wire compositions disclosed herein utilize a high alloy metal core surrounded by a layer of copper or copper alloy to form a consumable electrode.
  • the low resistivity of the copper-containing layer permits the transfer of current to the contact tip as the wire is passed through, which reduces torch heat loss and minimizes or eliminates arc formation between the wire and contact tip.
  • the copper-containing layer also reduces abrasion and mechanical wear on the feeding components of the welding system that are often constructed from similar copper materials.
  • the welding wire compositions disclosed herein exhibit similar or greater performance over comparative unclad high alloy wire, while improving contact tip service life and maintaining weld strength without copper cracking.
  • Welding wire compositions disclosed herein generally include a high alloy metal core having a surrounding copper-containing layer.
  • high alloy metal can refer to an alloy comprising one or more metals and at least 8% (e.g., greater than about 10.5%), by weight, of alloying elements, such as: aluminum, bismuth, chromium, molybdenum, chromium/molybdenum alloys, cobalt, copper, manganese, nickel, silicon, titanium, tungsten, and/or vanadium.
  • the high alloy metal core may include high alloy metal having sufficient conductivity for currents and conditions applied in the selected welding process.
  • the high alloy core may include high alloy steels containing iron and greater than about 10.5 wt % of a component selected from any one or more of: aluminum, bismuth, chromium, molybdenum, chromium/molybdenum alloys, cobalt, copper, manganese, nickel, silicon, titanium, tungsten, and/or vanadium.
  • High alloy metals may include, for example: stainless steels, maraging steel, Cr—Mo alloy steels, nickel alloys such as 276, 625, 718 nickel alloys, a combination thereof, and/or the like.
  • Welding wire compositions incorporating a high alloy metal core may also include a blend of any of the above alloys, including multi-phase and duplex stainless steels.
  • high alloy cores may include, for example, stainless steel compositions containing chromium at a percent by weight (wt %) of the high alloy metal core from about 12 wt % to about 18 wt %.
  • Suitable stainless steels may include one or more common grades (e.g., 200, 300, 400, etc.) of stainless steel, including martensitic, austenitic, or ferritic stainless steels.
  • the high alloy metal core may be a 300 grade austenitic stainless steel, such as a 302, 303, 304, 316, 310, or 321 grade stainless steel.
  • a copper-containing layer over a high alloy metal core may also carry advantages during production of the welding wire.
  • the use of a copper or copper alloy coating may function as a lubricant during wire drawing, minimizing or eliminating the need for additional additives or coatings.
  • the presence of a copper-containing layer may permit direct draw to a suitable working diameter from a larger stock to produce a welding wire compositions, and at increased speeds relative to unclad stainless steel wire.
  • the welding wire composition can comprise multiple copper-containing layers.
  • a plurality of copper-containing layers can surround the high alloy metal core.
  • the one or more copper-containing layers may include copper and copper alloys that are clad or bonded to the high alloy metal core by any appropriate process.
  • additional coating layers such as nickel, may be introduced during fabrication of the copper-containing layer that may enhance compatibility with the high alloy metal core.
  • Suitable copper alloys include alloys of copper and one or more of the metals selected from: nickel, zinc, chromium, cadmium, and/or tin. Copper alloys disclosed herein may include copper at a percent by weight (wt %) of the copper alloy up to about 90 wt %, up to about 95 wt %, up to about 99 wt %, or up to about 99.9 wt %.
  • the copper alloy may include copper at content by percent weight of the alloy ranging from about 60 wt % to about 95 wt %, or about 60 wt % to about 99.9 wt %.
  • the welding wire composition comprises a plurality of copper-containing layers
  • one or more of the copper containing layers can have alternative material composition (e.g., the copper content within a first copper-containing layer of the welding wire composition can be greater than the copper content within a second copper-containing layer).
  • the selection of copper or copper alloy as a surrounding layer may depend on a number of factors, including welding process type and metal composition of the workpiece. In some cases, depending on the nature of the high alloy metal in the core, the surface tension of the copper-containing layer may be tuned, for example, by modifying the copper content of the alloy to minimize migration of the copper into the grain boundaries of the weld metal.
  • the thickness of the copper-containing layer may also vary depending on the particular application. Welding wire compositions may include a high alloy metal core having a copper-containing layer arranged thereon, where the thickness of the copper-containing layer is greater than about 0.01 ⁇ m, greater than about 0.1 ⁇ m, greater than about 1 ⁇ m, and the like. In some embodiments, the copper-containing layer may have a thickness ranging from about 0.1 ⁇ m to about 100 ⁇ m.
  • the copper containing layer may be present at a percent by weight (wt %) of the welding wire ranging from about 0.005 wt % to about 3 wt %, about 0.005 wt % to about 2 wt %, or about 0.005 wt % to about 1 wt %.
  • the copper-containing layer may include up to about 5% of the cross-sectional area of the welding wire, including up to about 0.01% to about 5% of a cross-sectional area of the welding wire in some embodiments.
  • the components of the welding wire compositions may also be adapted to produce flux-cored welding wires having a flux material surrounded by a high alloy metal sheath with a copper-coated layer arranged thereon.
  • Welding wire compositions disclosed herein may be drawn or otherwise manufactured to any suitable diameter for the selected welding process (e.g., 0 to 30 gauge or more).
  • welding methods disclosed herein may include applying an electrical current sufficient to convert a welding wire composition to a molten state, the welding wire including a high alloy metal core, and a copper-containing layer surrounding the high alloy metal core; and depositing the molten droplets onto a workpiece.
  • Welding processes are not regarded as particularly limited and may include gas-metal arc welding processes such as submerged-arc welding (SAW), gas tungsten arc welding (GTAW), gas metal arc welding (GMAW), shielded metal arc welding (SMAW), flux-cored techniques such as Flux-Cored Arc Welding (FCAW), and combinations thereof.
  • gas-metal arc welding processes such as submerged-arc welding (SAW), gas tungsten arc welding (GTAW), gas metal arc welding (GMAW), shielded metal arc welding (SMAW), flux-cored techniques such as Flux-Cored Arc Welding (FCAW), and combinations thereof.
  • a coated welding wire 100 that includes a core 102 and a layer 104 surrounding the core.
  • a portion of the layer 104 is removed from the coated welding wire 100 depicted in FIG. 1 to illustrate the inner core 102 that is coated along the length of the wire 100 by the layer 104 .
  • the core 102 is high alloy metal core
  • the layer 104 includes copper or a copper alloy.
  • a welding method 200 is illustrated.
  • Step 202 includes applying an electrical current sufficient to convert a welding wire to a molten state to produce a molten weld material, in which the welding wire (e.g., coated welding wire 100 ) comprises a high alloy metal core (e.g., core 102 ) comprising greater than about 10.5 wt % of the high alloy metal core of a component selected from: aluminum, bismuth, chromium, molybdenum, chromium/molybdenum alloy, cobalt, copper, manganese, nickel, silicon, titanium, tungsten, vanadium, or a combination thereof; and a layer surrounding the high alloy metal core, comprising copper or a copper alloy.
  • Step 204 includes depositing the molten welding material onto a workpiece.
  • Example 1 Weld Performance of Cu-Coated 302 Grade Stainless Steel
  • welds were produced using a copper coated stainless solid wire (Cu-Coated 302) and a comparative unclad 316LSi grade stainless steel (Unclad 316LSi). Both wire samples exhibited a 0.045′′ diameter. Testing was performed on an automated arc welding apparatus configured to apply a test weld at a controlled contact tip to work distance (CTWD). The test weld was formed on a 24′′ diameter pipe by continuous weld to minimize measurement interference from starting and stopping. Test welds were run until failure, typically indicated by spatter clogging the nozzle and contacting the workpiece. Weld conditions and settings are summarized in Table 1, where welds were made with constant voltage (CV) and pulse.
  • CV constant voltage
  • contact tip wear rates for Unclad 316LSi and Cu-Coated 302 were studied using an automated arc welding apparatus as discussed above in Example 1. Amperage and voltage measurements were recorded for each sample during testing at approximately 415-417 times per minute, and the effective CTWD was monitored. For all welding samples and conditions studied, there was little difference in amperage decline between samples. Specifically, the Unclad 316LSi sample exhibited a 7.5 amp drop after one hour, while the Cu-Coated 302 sample exhibited a 9.9 amp after one hour.
  • the percent increase of the bore area over time was much less for the copper-coated wire sample.
  • the rate of diameter increase for the copper-coated samples appears to be 2 ⁇ to 3 ⁇ less that the Unclad 316LSi.
  • the results indicate that the copper-coated stainless welding wire compositions disclosed herein may be used to improve contact tip service life when compared to uncoated stainless steel, without substantial changes to welding performance or weld strength.
  • the terms “a” and “an” and “the” and similar references used in the context of describing a particular embodiment (especially in the context of certain of the following claims) can be construed to cover both the singular and the plural, unless specifically noted otherwise.
  • the term “or” as used herein, including the claims, is used to mean “and/or” unless explicitly indicated to refer to alternatives only or the alternatives are mutually exclusive.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Nonmetallic Welding Materials (AREA)
US18/045,934 2021-10-15 2022-10-12 High alloy welding wire with copper based coating Pending US20230119577A1 (en)

Priority Applications (6)

Application Number Priority Date Filing Date Title
US18/045,934 US20230119577A1 (en) 2021-10-15 2022-10-12 High alloy welding wire with copper based coating
EP22801636.6A EP4415923A1 (en) 2021-10-15 2022-10-13 High alloy welding wire with copper based coating
CN202280064768.8A CN117980105A (zh) 2021-10-15 2022-10-13 具有铜基涂层的高合金焊丝
PCT/US2022/046541 WO2023064450A1 (en) 2021-10-15 2022-10-13 High alloy welding wire with copper based coating
JP2024521230A JP2024539608A (ja) 2021-10-15 2022-10-13 銅系コーティングを有する高合金溶接ワイヤ
KR1020247012025A KR20240087837A (ko) 2021-10-15 2022-10-13 구리계 코팅을 갖는 고합금 용접 와이어

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Application Number Priority Date Filing Date Title
US202163256290P 2021-10-15 2021-10-15
US18/045,934 US20230119577A1 (en) 2021-10-15 2022-10-12 High alloy welding wire with copper based coating

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US20230119577A1 true US20230119577A1 (en) 2023-04-20

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US18/045,934 Pending US20230119577A1 (en) 2021-10-15 2022-10-12 High alloy welding wire with copper based coating

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US (1) US20230119577A1 (enExample)
EP (1) EP4415923A1 (enExample)
JP (1) JP2024539608A (enExample)
KR (1) KR20240087837A (enExample)
CN (1) CN117980105A (enExample)
WO (1) WO2023064450A1 (enExample)

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JP2910248B2 (ja) * 1990-12-28 1999-06-23 大同特殊鋼株式会社 溶接用ステンレスワイヤ
CN113458653A (zh) * 2021-06-30 2021-10-01 南京钢铁股份有限公司 超低温高锰钢的埋弧焊焊丝及制备方法

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US3438755A (en) * 1966-10-19 1969-04-15 Nat Standard Co Welding wire
DE3104960A1 (de) * 1981-02-12 1982-08-26 W.C. Heraeus Gmbh, 6450 Hanau "feinstdraht"
JPH04339589A (ja) * 1991-05-14 1992-11-26 Daido Steel Co Ltd ガスシールドアーク溶接用ステンレスワイヤ
US5553640A (en) * 1992-06-27 1996-09-10 Hille & Muller Stainless steel strip plated with brazing alloy for multilayer tube manufacturing
US20070170152A1 (en) * 2006-01-25 2007-07-26 Lincoln Global, Inc. Electric arc welding wire
US20180193916A1 (en) * 2017-01-06 2018-07-12 General Electric Company Additive manufacturing method and materials
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CN110977248A (zh) * 2019-12-13 2020-04-10 郑州机械研究所有限公司 耐磨药芯组合物、耐磨焊丝及其制备方法与应用
CN112746236A (zh) * 2020-12-29 2021-05-04 暨南大学 一种抗菌防腐钛合金防护涂层及其制备方法与应用
CN112908536A (zh) * 2021-01-21 2021-06-04 杭州益利素勒精线有限公司 一种高性能铜包铝线

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